The trek out and back from the Northwest Overland Rally presented photographer Lance Hanson and Factor55’s Justin Andrews with the opportunity to hit the dirt roads and explore the northern Cascades. Stumbling upon the perfect waterfront camp spot, the duo availed themselves of a few hours of relaxation, and when their motivation was recharged, it was time to tackle a few vehicle repairs.
Before we go further, a little about Justin Andrews. If you haven’t had the pleasure of meeting Justin, we hope one day you do, but be prepared to spend some time listening to more than one of the many stories he has to tell. Justin has been working in the off-road and vehicle recovery worlds for over 8 years, doing everything from long-distance expedition recovery outfitting to on-the-fly winch rope repairs at King Of The Hammers. He resides in Idaho, where Factor55 winch accessory products are manufactured. His favorite movie is Point Break, which explains why you see him traveling from Idaho to the coast to practice surfing whenever he can.
As an expert in the kind of work Lance and Justin now had to deal with, Justin took time to showcase how to repair a winch rope in the field, and we’re going to give you a quick rundown.
Vehicle recovery can be inherently dangerous due to a multitude of variables, but for this example, we’re demonstrating with synthetic rope, which has become the standard for winch recovery due to ease of use, lightness, and safety factors. When a rope fails, it falls to the ground, whereas a metal cable can start flying around and destroying anything in its path. You can apply the tactics in this trail repair guide to field repairing winch rope or building a winch extension to help you reach the tree that’s just out of reach.
Step 1: Cut It Out
If your rope is damaged, you will need to cut the affected fibers to ensure you are getting full working strength. Any knife will eventually cut through, but thanks to its exceptional toughness, CPM-CruWear steel – found in the 539GY Anonimus, as well several other Benchmade knives – cuts through winch rope many times while maintaining its edge. Synthetic ropes are made up of high-density fibers that will quickly dull super sharp blades that lack the resilience of a steel such as CPM-CruWear, CPM-D2, or other tough tool steels.
Step 2: Measure It
Now that the rope line is cut, you can prep the rope to be threaded and buried. You can do this task by old school method with a tape and a ball-point pen, but we will be using Factor55’s Fast Fid to make quick work. Utilizing the measurements on the Fast Fid, 3/8” rope calls for 20-27” of rope to be buried. Measure out to the proper length and make a note of it.
Insert the end of the rope into the Fast Fid wire basket. This works like a classic finger trap. Compress the wire basket and insert the rope. Then, release tension on the wire basket and it will capture the rope.
Step 3: Stab It
Where we measured the rope length, we will take the red part of the Fast Fid and insert between fibers. Poke all the way through. Pull through until you leave adequate diameter for loop (determined if it’s for a ¾” thimble or winch extension loop).
*Optional* - To prevent the rope from creeping, repeat by inserting the Fast Fid between more fibers and doubling back.
Step 4: Bury It
In the middle of synthetic rope there is a tunnel. Insert the Fast Fid into the fibers and find the tunnel and feed the Fast Fid into about 20”-27” of rope.
Once you reach the intended length, exit the tunnel like so.
Step 5: Pull It Through and Detach It
Pull the rope through.
Release pressure on the wire basket to remove the rope end.
Step 6: Slice it up
Step 7: Pull It Through
Holding the loop end, work the outside rope down until the fanned rope disappears into the tunnel. Just like that, your rope will have full strength and be ready for recovery duties as needed!
The ability to repair winch rope or build a winch extension in the field is an invaluable skill for any off-roading or overlanding enthusiast. As demonstrated,, having the right tools and knowing the proper techniques can make all the difference when faced with a damaged winch rope or when you simply need to extend your reach for recovery. The steps outlined—cutting the rope, measuring, using a Fast Fid, and correctly burying the rope—ensure that your winch line maintains its strength and integrity, even in remote locations.
By utilizing durable equipment like a Benchmade knife and a Fast Fid for quick and precise work, you can confidently perform a field repair on synthetic winch rope and keep your recovery efforts moving forward. Whether you're fixing a winch cable on the trail or preparing for any unforeseen equipment challenges, knowing how to handle and maintain your winch rope gives you peace of mind and the resilience to tackle whatever comes your way in the great outdoors.
Commonly Asked Questions on Repairing a Winch Rope
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Q: What tools do I need to repair winch rope in the field?
A: To repair winch rope, you’ll need a strong, sharp knife (such as the Anonimus), a Fast Fid tool for threading and burying the rope, and optionally, a tape measure for accurate rope length. A knife with good toughness and edge retention is essential for cutting through tough synthetic rope fibers. -
Q: How do I know when my winch rope needs repair?
A: If your winch rope is frayed, cut, or damaged in any way that compromises its strength, it’s time to repair it. Even small nicks can weaken the rope, so it's essential to inspect it regularly. If the fibers are visibly fraying or the rope fails to hold when tensioned, it's an immediate sign for a repair. -
Q: Can I repair my synthetic winch rope without professional tools?
A: Yes, you can repair synthetic winch rope in the field with the right basic tools, such as a sharp knife and a Fast Fid tool. The Fast Fid allows you to bury the rope end and re-secure it, which is the critical part of the repair process. These tools are portable and ideal for field repairs. -
Q: How do I build a winch extension?
A: To build a winch extension, first measure the rope to the required length. Using a Fast Fid tool, bury the end of the rope inside the fibers, forming a loop large enough for a thimble or hook. Then, taper and trim the end to ensure it fits tightly and securely. The extension will allow you to reach further for recovery operations. -
Q: What’s the best way to ensure my winch rope stays strong after a repair?
A: To maintain the strength of your repaired winch rope, ensure that you bury the rope properly using the Fast Fid and allow for the correct length to be buried. After pulling the rope through and tapering the end, make sure the rope is tightly secured inside the tunnel, and avoid over-tightening or under-tightening the loop. This will restore full strength to the rope, ensuring it’s ready for recovery work.